Considerations for the Planning and Use of Industrial Steel Storage Racks Your Logo Goes Here! Presented by: Jeff Andrews, Elite Storage John Krummell, Advance Carlos Oliver, Frazier 2016 MHI Copyright claimed for audiovisual works and sound recordings of seminar sessions. All rights reserved.
Seminar Objectives The objective of this seminar is to expose the participant to the latest array of racking products available and how to make the best assessment for their facility. Topics include: Types of Steel - Structural and Roll Formed Racks Various storage racking configurations available Pros and Cons Budget costs Accessories RMI Repair Guidelines Q&A
Roll-Formed Racks
Structural Steel Racks
Selective Racking Pros: High Selectivity Lower Cost Cons: More Aisles Less Cube Utilization
Selective Double Deep Pros: Cons: Higher storage density Less expensive than 2 deep push-back Fork extensions Wider aisles Productivity loss Wider bays - 102 vs. 96
Drive-in and Drive-thru Racks Pros: High density storage Best suited for common products Cons: Narrow fork truck lane Slow through-put Possible damage to racks First in, last out (FILO) Requires pallets in good condition Requires large span of open space Poor utilization (60-70% typical)
Double Pallet Drive-In Racks Pros: Faster storage and retrieval 2-4 pallets at a time Less posts = 20% more storage per square foot of floor area Wider lane = less damage to racks from forklift Cons: Need same type products in each lane, low selectivity Slightly more expensive than standard drive-in
Push-Back Racks Pros: More selectivity and higher utilization than drive-in Carts can be modified for various size pallets Up to 6 pallets deep Faster through-put than drive-in Less rack damage Cons: LIFO (Last in, first out) Higher per pallet cost Needs more vertical space due to cart stacking and rail slope
Pallet Flow Racks Pros: High density storage deep lane First in, First out (FIFO) Cons: Most expensive style racks Slope of tracks takes vertical space Pallets sometimes get stuck Pallet specs are CRITICAL Style of pallet? Plastic / Wooden? Board Direction? Weight? Max and min. Brakes? Pitch?
Carton Flow Racks Available with: Pencil Roller Beds - Fixed Track/Box Width Staggered Wheels - Easy to adjust lane size Used for: Case picking Open case picking Back-up stock Multiple size boxes Fits in standard racks or Separate support frames
Mezzanines Rack Supported Wide Span
Mezzanines for Optimizing Space
Pick Modules Pick, pack and ship operations Multiple styles of rack (carton flow, push-back, selective, pallet flow) Integrated with conveyor systems Lighting Sprinklers
Pick Modules Pallet flow picking Trash conveyor openings
Archive Storage Racks Narrow Aisle 30 Catwalk Systems
Multi-Level Records Storage (and/or Parts Storage) with VRC
Hi-Rise AS/RS and Pick Modules 40-120 Tall AS/RS Cranes Pick Module Platforms Pallet Flow Carton Flow Conveyor Systems Rack supported buildings Highest cost racks per pallet position Tight tolerance requirements
Pallet Shuttle Systems Pros: Semi-Automatic loading and unloading Increased productivity and throughput Less forklifts and operators required Reduced labor costs Less damage to products and racks Depth of tunnel is limitless High density - 85% space utilization FIFO & LIFO Multiple size pallets in the same lane Cons: Maintenance and recharging of shuttles Must move shuttles Limited to number of shuttles Productivity vs push-back is less Suited for clearing entire lanes not single pallets
Budget Price Review Selective Racks: Double Deep Racks: Drive-in Racks: Push-back Racks: Pallet Flow Racks: Shuttle Racks: $65-75 per pallet $75-85 per pallet $95-110 per pallet $100-175 per pallet $200-300 per pallet $150-250 per pallet
Cantilever Racks Structural Roll Formed Retail Lumber Furniture Steel Service Home Improvement Odd size products
Accessories Wide Selection
Accessories Guard rails Column protectors Rail guidance
RMI Guideline for Assessment and Repair or Replacement of Damaged Rack Agenda Why is Rack Repair Important? Repair and Replacement Principles Repair Options and Implementation
Damaged and Poor Repair
Damaged and Poor Repair
There can be Consequences for Ignoring Damage
Principle/Owner Responsibility Maintenance and safe operation of the system Ensuring that all work is performed under engineering supervision Maintenance and retention of system documentation
Supervising Engineer All work overseen by a All Supervising work overseen Engineer by a Supervising Engineer Each project must be evaluated individually Each project must be evaluated individually
Principles Evaluate the System Rack repair design must address all of the loads imparted on the damaged members (static, seismic, etc.), not just the individual members being repaired The Supervising Engineer determines the scope of the analysis required RMI/ANSI standards provide the framework for most of the design work
Principles Rack Systems Must Meet Code Documented systems still in place Can be evaluated under original codes Undocumented or relocated systems Must be evaluated under current building codes The process/designation is at the Supervising Engineer s discretion
Repair Options Replacement vs. Repair Kits are both viable options - as long as engineering work is performed Benefits and downsides for both Field welding is discouraged
Repair Assessment Process/protocol developed and overseen by Supervising Engineer Field assessor can perform work Recommend to fix all damage identified in need of repair
Repair the System vs. Repair the Component Owner reconfiguration reduced capacity of rack from 3,000 lbs. to 1,800 lbs. Do not repair rack without first validating capacity.
Engineering Refer to RMI/ANSI Specifications LARC drawings are required At a minimum for the repaired section Do not intend to force a full warehouse to be evaluated Discuss special conditions Column splice Bracing Foot plates and anchors Beams and intermembering
Installation Straight and Plumb (the entire frame) Splice cut joint tolerances Working with jacks Anchoring Hardware reuse
Repair Summary Guideline has been released and is available through the RMI website RMI Guideline for Assessment and Repair or Replacement of Damaged Rack www.mhi.org/rmi
Used Racking Considerations: Damage? Comingling parts from different manufacturers? Is manufacturer still in business? Has the supplier provided structural calculations or proof of capacity? Engineering just like new Permits still required
Members Advance Storage Products Atlanta Pallet Rack Bulldog Rack Company Elite Storage Solutions, LLC Engineered Products Equipement Boni Inc. Frazier Industrial Hannibal Industries, Inc. Husky Rack & Wire Interlake Mecalux Inc. Konstant Nanjing Huade Necochea Nedcon USA, Inc, Ridg-U-Rak, Inc. SpaceRak Speedrack Products Group, Ltd. Steel King Industries, Inc. Twinlode Corporation Unarco Material Handling, Inc. Storage Rack Decking Group Members: Cornerstone Specialty Wood Products DACS Husky Rack & Wire ITC Manufacturing J&L Wire Cloth LLC Nashville Wire Products, Inc. Ohio Gratings Prodeck 50 Inc. Worldwide Material Handling
Q & A
For More Information: www.mhi.org/rmi OR Jeff Woroniecki Managing Director for RMI jworoniecki@mhi.org 704-676-1190